Modular building connector

ABSTRACT

A connector assembly, having an upper connector coupled to a lower connector and a gusset plate sandwiched between the upper and lower connectors. The upper and lower connectors allow for coupling to adjacent upper and lower connectors, respectively, allowing for addition of a modular unit to a pre-existing modular structure. Also, ways of coupling adjacent upper connectors and coupling of adjacent lower connectors when coupling a modular unit to a pre-existing modular structure are provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national phase application filed under 35U.S.C. § 371 of International Application No. PCT/CA2018/050065, filedJan. 19, 2018, designating the United States, which claims the benefitof and priority to U.S. Provisional Patent Application No. 62/448,123filed Jan. 19, 2017 under the title MODULAR BUILDING CONNECTOR. Thecontents of the above patent applications are hereby expresslyincorporated by reference into the detailed description hereof.

FIELD

The invention relates to a connector, a connector assembly, a method forcoupling modular frame units having the connector assembly, a method ofassembling a modular unit having the connector assembly and a buildinghaving the connector assembly.

BACKGROUND

Prefabricating modular building units constructed from standardizedcomponents in a controlled factory setting can be desirable due to thelowered costs and the increased quality which is obtainable incomparison to performing similar work on an outdoor construction jobsite.

Thus prefabricated modular building units having a floor, walls and anoverhead structure, and which contain all the systems and furnishingspre-installed within them are preferred and known in the art. Buildingassembly systems composed of the means and methods to join two or moremodular building units together to form a larger structure are alsoknown in the art.

PCT application numbers PCT/CA2014/050110, PCT/CA2015/050369,PCT/CA2016/050434 and PCT/CA2016/050954 (the contents of which areincorporated herein by reference) disclose connectors and connectorassemblies that can be used for fabricating a modular unit and building.

There is a need in the art for a connector assembly that be used forcoupling a pre-fabricated modular unit to a pre-existing modularbuilding. In addition, there is a need in the art for a connector blockthat can be used to form the connector assembly described above.Further, there is a need in the art for a method of coupling apre-fabricated modular unit to a pre-existing modular building to expandthe footprint of the modular building.

SUMMARY

In one aspect, the specification relates to a connector assemblycomprising an upper connector coupled to a lower connector and a gussetplate sandwiched between the upper and lower connectors,

the lower connector having:

a lower connector body having a lower connector body column receivingend and a lower connector body gusset contact end, the column receivingend being adapted for receiving a first end of a first module frame andthe gusset contact end being adapted for coupling to the gusset plate;

at least a pair of lower connector arms, each lower connector armcoupled to and extending from the lower connector body and having lowerconnector arm inner face, a lower connector arm outer face, a lowerconnector arm gusset contact face, a lower connector arm load bearingface and a lower connector arm beam contact face, the beam contact facebeing positioned distal from the lower connector body, each lowerconnector arm having at least one fixing aperture on the load bearingface for receiving a fastening means to couple the lower connector tothe upper connector, and each lower connector arm having a hole formedthat extends from the lower connector arm inner face to the lowerconnector arm outer face; and

a lower connector arm boss coupled to and extending from the beamcontact face of each arm, the boss having a lower connector arm weldreceiving bevel extending from the distal end of the arm;

the upper connector having:

an upper connector body having an upper connector body column receivingend and an upper connector body gusset contact end, the column receivingend being adapted for receiving a first end of a second module frame andthe gusset contact end being adapted for coupling to the gusset plate;

at least a pair of upper connector arms, each upper connector armcoupled to and extending from the upper connector body and having anupper connector arm inner face, an upper connector arm outer face, anupper connector arm gusset contact face, an upper connector arm loadbearing face and an upper connector arm beam contact face, the beamcontact face being positioned distal from the upper connector body; eachupper connector arm having at least one upper connector arm fixingaperture for receiving a fastening means to couple the lower connectorto the upper connector and at least one upper connector arm gussetcoupling aperture for receiving a second fastening means to couple theupper connector to the gusset plate, and each upper connector arm havinga hole formed that extends from the upper connector arm inner face tothe upper connector arm outer face; and

an upper connector arm boss coupled to and extending from the upperconnector arm beam contact face of each upper connector arm, the bosshaving an upper connector arm weld receiving bevel extending from thedistal end of the arm;

the gusset plate having:

a gusset plate first face, a gusset plate second face and gusset platethrough holes for receiving the coupling and fastening means to couplethe upper connector and the lower connector.

In another aspect, the specification relates to lower connector having:

a lower connector body having a lower connector body column receivingend and a lower connector body gusset contact end, the column receivingend being adapted for receiving a first end of a first module frame andthe gusset contact end being adapted for coupling to the gusset plate;

at least a pair of lower connector arms, each lower connector armcoupled to and extending from the lower connector body and having lowerconnector arm inner face, a lower connector arm outer face, a lowerconnector arm gusset contact face, a lower connector arm load bearingface and a lower connector arm beam contact face, the beam contact facebeing positioned distal from the lower connector body, each lowerconnector arm having at least one fixing aperture on the load bearingface for receiving a fastening means to couple the lower connector tothe upper connector, and each lower connector arm having a hole formedthat extends from the lower connector arm inner face to the lowerconnector arm outer face; and

a lower connector arm boss coupled to and extending from the beamcontact face of each arm, the boss having a lower connector arm weldreceiving bevel extending from the distal end of the arm;

In a further aspect, the specification relates to an upper connectorhaving:

an upper connector body having an upper connector body column receivingend and an upper connector body gusset contact end, the column receivingend being adapted for receiving a first end of a second module frame andthe gusset contact end being adapted for coupling to the gusset plate;

at least a pair of upper connector arms, each upper connector armcoupled to and extending from the upper connector body and having anupper connector arm inner face, an upper connector arm outer face, anupper connector arm gusset contact face, an upper connector arm loadbearing face and an upper connector arm beam contact face, the beamcontact face being positioned distal from the upper connector body; eachupper connector arm having at least one upper connector arm fixingaperture for receiving a fastening means to couple the lower connectorto the upper connector and at least one upper connector arm gussetcoupling aperture for receiving a second fastening means to couple theupper connector to the gusset plate, and each upper connector arm havinga hole formed that extends from the upper connector arm inner face tothe upper connector arm outer face; and

an upper connector arm boss coupled to and extending from the upperconnector arm beam contact face of each upper connector arm, the bosshaving an upper connector arm weld receiving bevel extending from thedistal end of the arm;

In another further aspect, the specification relates to a method offorming a connector assembly having a lower connector, an upperconnector, a gusset plate, a second lower connector and a second upperconnector, wherein the lower connector, the upper connector, the gussetplate, the second lower connector and the second upper connector are asdisclosed herein, the method comprising the steps of:

positioning the lower connector, the upper connector, the gusset plate,the second lower connector and the second upper connector;

coupling the lower connector to the upper connector;

coupling the second lower connector to the second upper connector;

coupling the lower connector to the second lower connector; and

coupling the upper connector to the second upper connector.

In still another further aspect, the specification relates to a methodof coupling adjacent modular buildings, wherein the modular buildingstogether have a lower connector, an upper connector, a gusset plate, asecond lower connector and a second upper connector, wherein the lowerconnector, the upper connector, the gusset plate, the second lowerconnector and the second upper connector are as disclosed herein, themethod comprising the steps of:

positioning a first modular unit of a first modular building adjacent toa modular unit of the other modular building;

coupling the lower connector of the first modular unit of the firstmodular building to the second lower connector of the modular unit ofthe other building; and

coupling the upper connector of the first modular unit of the firstmodular building to the second upper connector of the modular unit ofthe other building.

In still another further aspect, the specification relates to a modularbuilding comprising a lower connector, an upper connector, a gussetplate, a second lower connector and a second upper connector, whereinthe lower connector, the upper connector, the gusset plate, the secondlower connector and the second upper connector are as disclosed herein.

Reference will now be made, by way of example, to the accompanyingdrawings which show example embodiments of the present application, andin which:

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made, by way of example, to the accompanyingdrawings which show example embodiments of the present application, andin which:

FIG. 1 is a perspective view of a pre-assembled modular unit forconnection to a pre-existing modular building prior to coupling the twounits;

FIG. 2 is a perspective view of a modular building after coupling of amodular unit shown in FIG. 1;

FIG. 3 is an exploded perspective view of a 90° connector with a partialcolumn and partial hollow structural sections (HSS);

FIG. 4 is an assembled perspective view of a 90° connector with apartial column and partial hollow structural sections (HSS);

FIG. 5 is an exploded perspective view of a 180° connector with apartial column and partial hollow structural sections (HSS);

FIG. 6 is an assembled perspective view of a 180° connector with apartial column and partial hollow structural sections (HSS);

FIG. 7 is an exploded perspective view of two adjacent 90° connectorassemblies with partial columns and partial hollow structural sections(HSS);

FIG. 8 is an assembled perspective view of two adjacent 90° connectorassemblies with a partial column and partial hollow structural sections(HSS);

FIG. 9 is a perspective view of a 90° connector prior to coupling withan adjacent 90° connector;

FIG. 10 is a perspective view of a 90° connector after coupling with anadjacent 90° connector;

FIG. 11 is a perspective view of a 180° connector prior to coupling withan adjacent 180° connector;

FIG. 12 is a perspective view of a 180° connector after coupling with anadjacent 180° connector;

FIG. 13 is a perspective view of three 90° connectors prior to coupling;

FIG. 14 is a perspective view of three 90° connectors after coupling;

FIG. 15 is a perspective view of four 90° connectors prior to coupling;

FIG. 16 is a perspective view of four 90° connectors after coupling;

FIG. 17 shows an exploded partial perspective view of two adjacentmodules before coupling of adjacent lower connectors;

FIG. 18 shows a partial perspective view of two adjacent modules aftercoupling of adjacent lower connectors;

FIG. 19 shows an exploded partial perspective view of two adjacentmodules having diagonal bracing before coupling of adjacent lowerconnectors; and

FIG. 20 shows a partial perspective view of two adjacent modules havingdiagonal bracing after coupling of adjacent lower connectors;

Similar reference numerals may have been used in different figures todenote similar components.

DESCRIPTION

A challenge exists with expansion of pre-existing modular buildings. Forinstance, where additional modular units are laterally attached toexpand the footprint of a pre-existing modular building. FIG. 1 show apre-existing modular building 2 having multiple floors. To expand thefootprint of the building, multiple modules at different levels must beconnected to the pre-existing modular building 2. To independentlyconnect each module on every level to the pre-existing modular building2 can be challenging, and also result in loss of structural strength ofthe final modular building. In addition, coupling a pre-fabricatedmodular unit 4 to a pre-existing modular building 2 to form an expandedmodular building 6 (FIG. 2) can also pose its challenges. For instance,it can be difficult to connect the corner connectors of each module onevery floor of the pre-existing modular building 2 with the cornerconnectors of each module on every floor of the pre-fabricated modularunit 4, while maintaining the overall structural strength and avoidingflexion at the interface of the modular building 2 and modular unit 4.In addition, a similar challenge can exist when coupling additionalmodules, one-by-one, to a pre-existing modular building, as coupling aconnector assembly of the new module to be added to the connectorassembly of the pre-existing modular building can be difficult, whilemaintaining structural strength.

PCT application numbers PCT/CA2014/050110, PCT/CA2015/050369,PCT/CA2016/050434 and PCT/CA2016/050954 (the contents of which areincorporated herein by reference) disclose connector assemblies, modularunits, methods of coupling connectors and methods of constructingmodular units and buildings, along with additional information thatrelates to the specification, including the connectors, disclosedherein.

The specification has been initially subdivided in to a section for eachcomponent or group of components for convenience in reading.

Corner Blocks

The specification discloses upper or lower load-bearing connectors orblocks, which in one embodiment are corner blocks. In a particularembodiment, the blocks are substantially quadrilateral and in otherembodiments have polygonal or asymmetrical shapes. These blocks can bemass-produced with features that provide a multiplicity of functions soas to concentrate the precision operations in a small number and size ofobjects and reduce the amount and complexity of work that must beperformed on other members. The upper and lower blocks can be ofdistinct forms and, in one embodiment, are located on the upper andlower ends of the vertical corner members (columns) of generallyangular, tubular or built-up form, which perform the function ofmulti-story columns when modules so constructed are joined using thefeatures on the blocks to form a larger or taller structure.

Likewise other features on the blocks engage the horizontal members ofthe building and perform the function of continuous horizontal memberswhen modules so constructed are joined to form a larger or widerstructure.

In a particular embodiment, the blocks have arms projecting at aplurality of angles including but not limited to perpendicular to thefaces of the blocks providing for the location and welding of adjoiningmembers at a plurality of angles. In a particular embodiment, thepresent invention thus facilitates the fabrication and erection ofmodules including but not limited to orthogonal, tapering, radiating andcurving shapes. The threaded and unthreaded holes in the arms achievethe positioning of threaded fasteners and the vertical walls of the armsprovide an increase in the load-bearing capacity and transmission of thecompression and tension forces created by the forces acting on thebuilding and by the action of the fasteners.

In a particular embodiment, the blocks have holes in both the body andthe arms for the passage and receiving of bolts with nuts or arethreaded to receive bolts, so as to provide continuity of verticaltension through the columns and a moment resisting interconnectionbetween adjacent modules or other building structures. The tensionresistance resulting from the connection of the columns in the verticalplane enables the structure to resist uplift where it occurs andproduces friction on the gusset plate so as to convey forces to thelateral members in the horizontal plane with a high level of fixity.

More specifically, during assembly, the surface of the arms which bearagainst the gusset plate from both above and below are made tight.

In a particular embodiment, the bolts are accessible within the wallcavity or other such places and can be arranged flush or below thesurface such that a removable patch can be easily configured to coverthe location of the bolt and ensure continuity of the fireproofingmaterials surrounding the load-bearing structures. In a particularembodiment as with connection to the underside of a roof assembly, thebolts may be inserted from the bottom up.

In a particular embodiment, the blocks have projecting features on thedistal end faces of the block located to provide backing for theassembly welding, reducing the structural impact of a weld to aconnecting member that is cut too short or with an out-of square end orother imperfection reducing the probability of a worker executing anon-conforming welded connection between the corner blocks and themembers which are welded to the block and a beveled feature so locatedon the outside of the block located so as to reduce the likelihood thata weld will require grinding so it does not project beyond the surfaceand conflict with an adjoining module.

The holes in the corner blocks provide a means of connection totie-downs and hoisting devices. In a particular embodiment, the upperface of the block is prepared with an opening in to which aquick-release connector can be inserted so as to provide a means ofquickly and dependably connecting and disconnecting the module to alifting device.

In a particular embodiment the blocks have features on the contact faceswhich engage with corresponding features on the gusset plate so as toincrease the resistance to slippage along the contact plane as mightoccur during a seismic event.

In a particular embodiment, the blocks have projecting flanges co-planarwith the faces to which floor or ceiling finishes are to be applied toprovide a continuous backer in the area of the fastener access leave-outso as to improve air-tightness and provide support to the flooring orceiling material. In use, the flooring material covers the top face ofthe frame up to the end of the arms of the block, but is cut away at theblock to expose the top face to allow for the insertion of the bolts forassembly. This can leave the flooring unsupported. The flange shown canhelp to support the floor in that area and to create a continuoussurface so there is no crack in the sealing between floors, which canhelp with fireproofing.

In a particular embodiment the blocks have a multiplicity of holes onthe vertical surface for the connection of accessories such asbalconies, hallways and facade treatments.

In a particular embodiment, the blocks have one, two, three or moreholes for the passage of vertical tension fasteners and there is onesuch hole for each vertical structural member which may be centeredabove it. In another particular embodiment, there are two or more holesfor each vertical member. The length of the arms on the blocks throughwhich the fasteners pass and the length of the arms on the gusset platebetween the blocks vary in relation to the number of such holes.

In a particular embodiment the lower block has openings through the faceso as to reduce the amount of steel which must be drilled or otherwiseremoved from the casting to allow passage of the bolts. In combinationwith this feature or separately the block may be reinforced with ribs toas to augment the load bearing capacity and resistance to twisting.

Another component is a block having features on its one end prepared toreceive a tubular structural member of one dimension and having featureson the other end prepared to receive a tubular member of anotherdimension, or the corresponding features of a block, and having taperedsides and internal ribs or other reinforcing means so as to transmit theforces between the two members without distorting. As previouslydescribed in the PCT applications noted above, it can be desirable tochange sizes of columns in relation to the load. Smaller columns areused in the upper parts of the building where loads are smaller, largercolumns in the lower parts where load are higher due to the accumulatedgravity load and increased overturning forces.

Another component is a block configured so as to allow a columnfabricated from plate to be welded to its exterior vertical faces so asto bear directly on and connect to a connection prepared in a similarmanner or a block of the types previously described. As can beappreciated by someone knowledgeable in the art two or more such columnsjoined in to a T or X configuration can achieve both large weights perfoot and increased cross-section resulting in greater bucklingresistance without projecting in to the occupied spaces of a building.

Gusset Plate

Another component is a plate which is interposed between the blocks atthe top and bottom ends of columns or groups of columns, which hasupward-facing tapered locating pins for engaging and directing adescending module by sliding contact with a corresponding locatingrecess on the underside of a the corner block thus locating the modulein the correct position for fastening. The plate also provides throughholes for use in connecting adjacent modules with bolts to providestructural continuity in the horizontal plane both during constructionand in the completed building and by virtue of its ductility, foraccommodating slight variations in column length so as to ensure acontinuous load path which bears equally on all members of the columngroup thus formed. As can be appreciated by someone knowledgeable in theart, the plate can be shaped to fit between a single vertical column orbetween two or more columns arranged in an orthogonal or otherdisposition. In a particular embodiment shims of a similar dimension andprepared with appropriate holes are placed in one or both sides of theconnection to accommodate for variations in the finished dimensions ofthe modules thus maintaining the correct geometry of the modules stack.

In a particular embodiment, the gusset plate is provided withprojections on its upper and lower faces which engage with correspondinggrooves in the contact faces of the blocks above and below so as toincrease the resistance to sliding movement as might occur during aseismic event and reduce the load which such movement would apply to theshanks of the vertical tension fasteners.

In addition to the gusset plate interposed between connectors at the topand bottom end of columns, a second gusset plate can also be used toconnect adjacent top connectors or bottom connectors. The second gussetplate used can have holes to receive fastening means, such as bolts, toaffix the second gusset plate to two adjacent top connectors, or twoadjacent bottom connectors, as described further herein.

Stairwells and Elevator Shafts

The system disclosed herein allows for the fabrication of modules withinwhich are installed stairs or elevating devices and which separate atthe mateline between two modules without a significant visual orfunctional disruption.

Overheight Modules

The system disclosed herein allows for the fabrication of modules whichcomprise the upper and lower halves of habitable volumes which aretaller than shipping restrictions will normally allow and which arejoined at the mateline between two or more stacked modules without asignificant visual or functional disruption.

Hallways

Another group of components disclosed is a structural hallway floor thatis made from a suitable material such as reinforced concrete, sandwichplate, wood or formed metal together with supporting pedestals. In aparticular embodiment, the slab is composed of reinforced concrete withreinforcement bars placed so that features on the support pedestalsengage them so as to resist bending of the pedestals, thus creating amoment connection between stacks of adjacent modules thus connected. Thepedestals are provided with holes that align with corresponding holes inthe upper and lower corner blocks and serve to connect two parallelstacks of modules as well as connecting the adjacent columns within astack on one side so as to create a combined load path. The pedestalsand floor slabs may also be connected to the sides or ends of a stack ofmodules on one side of the slab and a balcony support frame on theoutside to form a building with balconies or breezeways. The floor slaband pedestal assemblies can also be used as convenient carriers forbuilding services such as ducts, pipes and wiring to facilitate thefabrication of these components off site in the factory environment.

In a particular embodiment the gusset plate can be extended as requiredand provided with holes for the passage of fasteners to support andengage accessory support and connection assemblies of a variety ofsizes.

System of Interdependent Detailing

The present invention also comprises a pre-determined grid upon whichthe dimensioning of the interconnected elements of subject building arebased together with a system of fixtures which ensure the grid ismaintained throughout all fabricated assemblies in all axes whichensures an accurate and interdependent relationship extending fromcorner blocks, to members, to subassemblies, to modules and to wholebuildings in all axes. The dimensioning system thus serves to reducefractional element and module sizing, to increase the number of commonparts and to reduce the difficulty of coordination with foundation andpodium contractors and which facilitates the work of all internal orexternal suppliers of components to be integrated in the modules sofabricated.

In a particular embodiment, the system is based on increments of no moreor no less than two inches in three axes with a centre-to-centreaccuracy between holes used for fastening of plus or minus 1/32″ and anoutside to outside dimensional accuracy of all mating surfaces of plus0″ minus 1/16″.

Fixtures

The present invention includes a system for the assembly of the moduleframes which ensures that modules conform to the grid established above,and that no part of a module projects beyond the outermost idealdimension, which increases the achievable speed of assembly and accuracyof the structure and, eliminates the possibility of additive dimensionaldrift, resulting in a reduction in the difficulty of erection, thedifficulty of fireproofing, the possibility of interconnecting moduleswith a greater degree of fixity and a reduction in wall thickness andwasted space.

Reinforcing Members

Further the invention comprise a system of standardized reinforcingmembers which connect with each other and with the columns, lateralframing, diagonal bracing and corner blocks described herein,eliminating the need for case-by-case design and fabrication orcustomization of reinforcement components.

Reinforcement Analysis

Further, the present invention comprises a work method forsystematically analysing the forces acting on a building composed ofmodules, defining the optimum location for the application of thestandardized reinforcing systems, selecting from a list of standardizedreinforcements with progressive buckling and uplift resistance andthereby incorporating only such reinforcements as are minimallynecessary to strengthen the areas under additional stress, withoutadding unnecessary structural material to more locations than required,without significantly disrupting the application of fireproofingmaterials and without requiring additional thickness of the walls of themodule.

Built Up Columns

Further, the present invention comprises a method for the fabricationand connection of the outer columns so they form groupings with greaterresistance to the compressive and tensile forces resulting from theloads encountered in the construction of tall and/or slender buildings.

In a particular embodiment the resistance to horizontal drift, bucklingand uplift of the columns is increased by joining two or more columns bywelding along their vertical edges or other suitable means in to groupsand welding or otherwise attaching these groups to the connector blocksin the areas provide for the purpose.

In a particular embodiment the columns are comprised of plates joined bywelding or other suitable means along their edges and these assembliesare welded or otherwise joined to the blocks. In a particular embodimentthese plates are 1″ or more in thickness. In another particularembodiment, the plate columns by-pass the blocks to which they arewelded and make contact with the top and bottom faces of the gussetplate along the ends of the plates.

In a particular embodiment the columns are progressively larger andengage blocks having correspondingly larger bodies and connectionfeatures. In a particular embodiment these columns are 4″ square, 6″square, 8″ square, 10″ square, rectangular and so on, or the metricequivalents, corresponding to standard structural hollow metal orcomposite sections.

Benefits

Increases Height without Frame

By eliminating the risk of inadvertently creating a connection which isnot fully compressed during assembly and which is therefore not fullyfixed, and by providing for a larger number of fasteners, and byfacilitating the placement of the reinforcement, the system ofcomponents and work methods of the present invention can serve toincrease the height of a building which can be built without therequirement for a secondary external or internal bracing frame, and toincrease its useable floor area due to involving a larger portion of themembers in the structural function and the enhanced fixity of theconnections, the creation and assurance of multiple and redundant loadpaths, the integration of the brace frame in to the module walls and theresulting efficient transfer of the external, internal and self-loadsimposed on the completed building through the adjacent modules andthence to the ground.

Increases Height with Frame

By reducing the amount of steel required in upper floors and thus itstotal weight, this invention also serves to increases the height of abuilding which is built with the use of a secondary external or internalbracing frame of a given size.

Reduces Number of Unique Parts, Number of Locations and Size of Members

By analyzing the loads applied and more efficiently involving more ofthe required members in the structural function the invention alsoreduces the size of members required and limits the number, size andlocations where unique reinforcement details and the related complexityof the fireproofing is required, thereby reducing the cost of suchbuildings.

Reduces Requirement for Precision

The present invention can help to further reduces the precision of theparts which must be made by workers in the modular production facility,which reduces the cost of the fabrication.

Reduces Complex Fabrication

The present invention concentrates many of the complex features requiredto join members, hoist modules and join modules in a singlemass-produced component, helping to reduce both the complexity and therequirement for skilled work necessary to construct a module.

Allows Taller and Wider

Additionally the system can allow the building of taller modulescomposed of two stacked frames one of which has openings in the ceilingand the other of which has openings in the floor, longer modules due tothe performance of the bracing and wider modules due to the improvedbehavior of the apertures in the ends, thus providing greaterflexibility to designers of buildings so constructed.

Reduces Wall Thickness

By better perfectly distributing the load-bearing components the presentinvention can help to reduce the wall thickness required to accommodatestructure and services.

Reduces Site Labour for Patching

By placing the tension connections within the wall cavity andconcentrating the connection means in the vicinity of the column, thepresent invention can help to reduce both the number and the extent ofthe leave-out areas which must be subsequently patched.

The invention in accordance with an embodiment disclosed in thespecification will now be described with reference to the accompanyingdrawings.

FIGS. 3 (exploded view) and 4 (assembled) disclose a 90° lower cornerconnector 8 (or block) that can be used to form the corner connectorassembly disclosed herein. The lower connector is generally made up oflower connector body 10, with arms 12 extending at 90° to each otherfrom the lower connector body 10. The lower connector body 10 at oneend, designated as the lower connector body column receiving end 14, isadapted for receiving and coupling to a column 16, post or otherstructural unit of a modular frame; while the other end, designated asthe lower connector body gusset contact end 18, is adapted for couplingto a first gusset plate 20 (as described herein).

In one embodiment, the lower connector column receiving end 14 can beprovided with features that can assist in coupling a column 16, post orother structural unit, such as weld receiving bevel and weld backerextending from the lower connector body weld receiving bevel, asdescribed in PCT application numbers PCT/CA2014/050110,PCT/CA2015/050369, PCT/CA2016/050434 and PCT/CA2016/050954 (the contentsof which are incorporated herein by reference). Such features can assistwith proper placement of column 16, post or other structural unity andfor forming a weld, and can in some embodiments, avoid requiring anymodification of the column, post or other structural unit.

In the embodiment disclosed herein, the lower connector body 10 isprovided with a lower connector body weld receiving bevel 22, and a weldbacker 24 extending from the weld receiving bevel 22. The lowerconnector body weld backer 24 can have a cross-section similar to thecross-section of the column 16, however, the weld backer 24 is sizedsuch that it can be inserted into the hollow structural section (HSS) toensure proper alignment of the column. In addition, the column 16 canhave holes 26 that can align with precision drilled holes 27 in the weldbacker 24, such that after alignment of the holes 26 in the column 16with holes 27 in the weld backer 24, the column can be affixed in placeusing fastening means 28, such as screws or bolts, while ensuring properpositioning of the column 16.

The lower connector body 10 is also provided with a lower connector bodygusset contact face 18 at the lower connector body gusset end 30, andthat can come in contact with a first gusset plate 20, as describedherein. In the embodiment disclosed herein, the lower connector bodygusset contact face 18 is generally planar. In one embodiment, forexample and without limitation, the lower connector body gusset contactface 18 can be provided with weep channels that can allow for drainageof any water, condensate or other liquid out of the lower connector 8.

In the embodiment shown in FIGS. 3 and 4, the lower connector 8 isprovided with a pair of lower connector arms 12 extending from the lowerconnector body 10. In addition, the arms are positioned to beperpendicular to each other, i.e., one arm extends at nearly 90° to thesecond arm. However, the position of the arms can be varied dependingupon the design and application requirements, and the arms can bepresent at angles less than or greater than 90°. For instance, FIGS. 5and 6, disclose a lower connector 8, where the arms 12 extend (inopposing directions) at 180° relative to each other.

Due to the placement of the lower connector 8 in a modular structure(FIGS. 1 and 2), the lower connector 8 is provided with a lowerconnector inner face 32 and a lower connector outer face 34. The lowerconnector inner face 32 is designated by the modular structure that isformed, with the face 32 of the connector 8 being positioned towards theinsider of the modular structure being considered as the lower connectorinner face 32, and the face of the lower connector 8 positioned awayfrom the inside (or towards the outside) of the modular structure beingdesignated as the lower connector outer face 34.

In the embodiment shown, the lower connector arms 12 has a lowerconnector arm load bearing face 36 and lower connector arm beam contactface 38, which can engage a beam 40 or other structural unit to form themodular structure. In the embodiment shown, the lower connector arm loadbearing face 36 lies is a plane different than the plane of the lowerconnector body column receiving end 14, with the plane of the lowerconnector arm load bearing face 36 being more closer to the plane havingthe lower connector body gusset end 30 than the plan of the lowerconnector body column receiving end 14. This result in the lowerconnector arm load bearing face 36 being spaced-apart from the lowerconnector body column receiving end 14, and can help with the weldoperation to form the modular structural unit.

The lower connector arm 12 can be provided with holes 42 that can beused for coupling of the lower connector 8 to the upper connector 102,and for forming the connector assembly 100, disclosed herein. In oneembodiment, as disclosed in the Figures, the holes 42 can be positionedcloser to the lower connector inner face 32, which can help to provide alower connector arm load bearing surface 36 positioned closer to thelower connector outer face 34. The lower connector arm load bearingsurface 36 can provide an area on the arms 12 for positioning andbearing the load of additional structural features of a modularstructure. In another embodiment, there can be more holes or less holesas required by the loads to be transmitted and the positioning of loadbearing elements bearing upon the surfaces of the blocks.

The arms 12 of the lower connector 8 are also provided with a boss 44extending from the lower connector arm beam contact face 38, which ispositioned at a distal end of the arms 12 that extend from the lowerconnector body 10. The boss 44 can be provided with features forcoupling of the lower connector arm 12 to the beam 40 or otherstructural unit of a modular frame. In one embodiment, the boss 44 isprovided with a lower connector weld receiving bevel 46, and which canassist in forming a weld with a beam 40 or other structural unit of amodular frame.

In one embodiment, for example and without limitation, the boss 44 canbe positioned towards one side of the beam contacting face 38 of thelower connector arm 8. In the embodiment shown in the figures, the boss44 is positioned proximate to the outer face 34 of the lower connector8, and is also spaced from the edge of the lower connector arm 12 closeto the lower connector inner face 32. By positioning the boss 44 closeto the outer face 34, a channel is provided on the beam contacting face38 of the lower connector arm 12 close to the inner face 32. The channelcan provide space for passing wires or other conduits in a modularstructure.

FIGS. 5 and 6 show a second embodiment of a lower connector 8 havingfeatures similar to the lower connector 8 embodiment disclosed in FIGS.3 and 4. The embodiment disclosed in FIGS. 5 and 6 have arms extendingin opposing directions, rather than being perpendicular to each other asshown in FIGS. 3 and 4. The direction of the arms 12 is not particularlylimited and can vary depending upon the application and designrequirements, as should be recognized by a person of skill in the artbased on the teaching in this specification.

In addition, the arms 12 of the lower connector 8 can have one or moreholes 48 formed, extending from lower connector inner face 32 to thelower connector outer face 34. The one or more holes 48 can receivefastening means 28 that allow for coupling of the lower connector 8 toan adjacent lower connector, as described further herein.

The upper connector 102 disclosed and used to form the connectorassembly 100 has features similar to the lower connector 8, describedabove. Additional details of the upper connector 102 can be found in PCTapplications numbers PCT/CA2014/050110, PCT/CA2015/050369,PCT/CA2016/050434 and PCT/CA2016/050954 (the contents of which areincorporated herein by reference). In addition, the upper connector 102can have holes 50 extending from inner face to the outer face of upperconnector arm 104 (similar to that seen in the lower connector), thatallow for coupling of the upper connector 102 to an adjacent upperconnector, as described further herein.

FIGS. 7 (exploded) and 8 (assembled) show a connector assembly 100 inaccordance with an embodiment disclosed herein, where a pair of adjacentlower connectors 8 is coupled to a pair of adjacent upper connectors102, sandwiching a gusset plate 20 in between. Each of the upperconnectors 102 have a pin 54 coupled to the upper connector gussetcontact face 106. As described in PCT application numbersPCT/CA2014/050110, PCT/CA2015/050369, PCT/CA2016/050434 andPCT/CA2016/050954 (the contents of which are incorporated herein byreference), the pin 54 is inserted in holes 56 in the gusset plate 54,and then the pin 54 engages holes (not shown) in the lower connectorgusset contact face 18, to ensure proper alignment when forming theconnector assembly 100.

To extend the footprint on an existing modular structure 2 by additionof a module unit 4 having multiple floors, the lower connectors in theexisting modular structure 2 can be coupled to lower connectors in themodule unit 4 that will lie adjacent to each other, upon assembly.Similarly, the upper connectors in the existing modular structure 2 canbe coupled to upper connectors of the module unit 4 to form the expandedmodular building 6, shown in FIG. 2.

FIGS. 9 (exploded) and 10 (assembled) show adjacent lower connectors 8prior to (FIG. 9) and after coupling (FIG. 10). The lower connector 8have holes 48 drilled transversely through lower connector arms 12,forming a channel and allowing fluid communication from the inner face32 to the outer face 34 of the lower connector 8. The number andposition of the holes 48 is not particularly limited and can be varieddepending upon the design and application requirements. In theembodiment shown, each lower connector arm 8 has a pair of holes 48,with a first hole 48 formed closer to the lower connector arm loadbearing face 36 and the other hole 48 formed closer to the lowerconnector gusset end 30. In addition, in one embodiment as shown in thefigures, the holes 48 are at a distal position from the lower connectorbody 10, or in other words, more closer to the lower connector arm beamcontact face 38. The actual position of the holes 48 to receivecross-bolts 28 is not particularly limited and can be varied dependingupon application and design requirements, so long as they are positionedon the arms 12 of the connectors, formed transversely and allow forcross-bolts 28 to be inserted to fasten adjacent connectors, asdisclosed herein. However, by positioning the holes 48 closer to aconnector arm beam contact face 38 improved fixity can be achieved whencoupling an adjacent connector.

To couple adjacent lower connectors 8, cross-bolts 28 can be used tofasten a first lower connector 8 to an adjacent second lower connector8. In one embodiment as shown in FIG. 9, a first bolt 28 is insertedinto a first hole 48 from the inner face 32 of a first lower connector8, which then engages a corresponding first hole 48 from the outer face34 of an adjacent second lower connector 8. In addition, a second bolt28 is inserted into a second hole 48 from the inner face 32 of thesecond lower connector 8, which then engages a corresponding second hole48 from the outer face 34 of the adjacent first lower connector 8. Inthe embodiment disclosed, the position of the holes 48 allow foralternating bolts 28 to be inserted to couple the adjacent lowerconnectors (see FIG. 9).

FIGS. 9 and 10 show coupling of adjacent 90° lower connectors, whileFIGS. 11 (exploded) and 12 (assembled) show coupling of adjacent 180°lower connectors, using cross-bolts 28, as described above. FIGS. 13(exploded) and 14 (assembled) show coupling of three 90° lowerconnectors 8 using cross-bolts 28, while FIGS. 15 (exploded) and 16(assembled) shown four 90° lower connectors 8 coupled using thecross-bolts 28, as described above.

Similar method can be used for coupling of the upper connectors 102, asdescribed above with respect to the lower connectors 8; which are alsoprovided with holes that are formed in a transverse plane of the arms104 extending from the upper connector 102.

FIGS. 17 (exploded) and 18 (assembled) show an alternate method ofcoupling adjacent modules when coupling a modular building 2 to amodular unit 4. In the embodiment shown in FIG. 17, a 180° lowerconnector is disclosed; however, as should be understood by a person ofskill in the art, similar to coupling the lower connector 8, upperconnectors 102 can also be coupled in a similar way.

Features and methods described above with respect to the connectors andmethods of coupling adjacent connectors can also be used when couplingadjacent connectors as disclosed in FIGS. 17 and 18. In the embodimentshown in FIGS. 17 and 18, a second gusset plate 52 is coupled to thelower connector arm load bearing face 36 using fastening means 28 thatcan be inserted into openings in the second gusset plate 52, which thenengage in one or more holes on the lower connector arm load bearing face36. The second gusset plate 52 upon coupling to the lower connector armload bearing face 36 lies in the same plane as the a sub-floor 152. Thesecond gusset plate used can be coupled to only a single arm 12 of thelower connector 8. Alternatively, as shown in FIG. 17 closer to the topof the figure page, when coupling adjacent lower connectors 8 to expandthe footprint of a modular building, the second gusset plate 150 used issized for coupling to two adjacent lower connector arms 12. Similar toother gusset plates 52, the gusset plate 150 used to couple to twoadjacent lower connector arms 12 have holes that can receive fasteningmeans 28 that engage the second gusset plate 150, as well as the twoadjacent arms 12 on the two adjacent lower connectors 8. This can helpwith affixing and ensuring that a smooth floor of the expanded modularbuilding 6.

FIGS. 19 and 20 show instances where diagonal bracing 154 is used in amodule. Similar to the embodiment shown in FIGS. 17 and 18, a secondgusset plate 150 is used to couple to the lower connector arm loadbearing face 36. In the embodiment shown in FIGS. 19 and 20, the secondgusset plate 150 is provided with projections 156 that have holes 156for receiving fastening means 28 for affixing the diagonal brace 154 tothe projections 156. When coupling adjacent lower connectors 8, thefastening means 28 can be removed from the projection 156, and thediagonal brace 154 can be pivoted (FIG. 20) about the opposing fixed endof the diagonal brace 154 to provide sufficient space to remove thesecond gusset plate 52 that only couples to a single arm 12 on a lowerconnector 8, and replace with a second gusset plate 150 that couples totwo adjacent arms 12 on adjacent lower connectors 8. Once the secondgusset plate 150 that couples to two adjacent arms 12 is in place, thediagonal brace 154 can be pivoted back into position to affix to thesecond gusset plate 150 installed.

In addition, the second gusset plate 150 can have additional projections156 with holes that allow for coupling to a second diagonal brace (FIG.19) and ensuring that the diagonal braces are aligned and affixedproperly to ensure fixity.

The terms “upper” and “lower” as used herein, and particularly withrespect to the connectors, are relative and can be interchanged.However, for the purpose of describing the connector assembly 100, upperconnector 102 refers to connector that would typically be positioned atan upper corner or upper end of a modular frame that can be lifted andpositioned on a second (or lower) modular frame. While lower connectors8 refer to connectors positioned on the lower corner or lower end of amodular frame, and that would be closer to ground or floor (than theupper connector).

In the embodiments shown, the upper corner connector 102 and lowercorner connector 8 can be made from hollow castings of steel. Theconnectors can have mechanical properties such as tensile strength andductility equal to or greater than mild steel and metallurgicalproperties such that the connector can be welded to mild steel withstandard practices such as structural metal inert gas (MIG) welding.

In a further embodiment, the upper and lower connectors (102, 8) eachhave a body, respectively, which in one particular embodiment can behollow. The upper connector body 108 and the lower connector body 10 canhave a variety of shapes depending upon the design and applicationrequirements. However, in the figures, the upper and lower connectors(102, 8) have a shape having a square cross-section.

In one embodiment, the connector bodies (108, 10) are 4″ square toaccept a 4″×4″ Hollow Structural Section (HSS). In another embodiment,the connector bodies (108, 10) are 6″ square to accept a 6″×6″ HSS.Connectors 102 and 8 have adequate thickness for the intended functionand details such as draft angles and uniformity of sections whichfacilitate casting. In a particular embodiment, the casting are drilledand surfaces milled to a high accuracy as measured between centres ofthe apertures and the other apertures, as well as the faces of theblock. Additionally, perpendicularity and parallelism are similarlymaintained to high tolerances, or other tolerances as may be convenient.In another embodiment, the connector is made by assembling one or moreof rolled sections, flat or brake-formed plate by welding or mechanicalmeans. In a further embodiment, the part is made by casting non-ferrous,plastic, cementitious or any other suitable material. In anotherembodiment, the portions of the blocks to which the columns and armswill be connected can have features to locate the HSS and facilitatewelding.

Certain adaptations and modifications of the described embodiments canbe made. Therefore, the above discussed embodiments are considered to beillustrative and not restrictive.

Parts list No. Description 2 Existing modular building 4 Pre-fabricatedmodular building unit 6 Expanded modular building 8 Corner connector 10lower connector body 12 lower connector arms 14 lower connector bodycolumn receiving end 16 Column 18 lower connector body gusset contactface 20 first gusset plate 22 lower connector body weld receiving bevel24 lower connect body weld backer 26 column holes 27 Holes in weldbacker 28 fastening means 30 lower connector body gusset end 32 lowerconnector inner face 34 lower connector outer face 36 lower connectorarm load bearing face 38 lower connector arm beam contact face 40 Beam42 lower connector arm holes on load bearing face 44 boss on lowerconnector arm 46 lower connector weld receiving bevel 48 holes extendingfrom inner to outer face of lower connector arm 50 holes extending frominner to outer face of upper connector arm 52 gusset plate 54 Pin 56holes in gusset plate to receive pin 100 connector assembly 102 upperconnector 104 upper connector arm 106 upper connector gusset contactface 108 upper connector body 150 Second gusset plate 152 Subfloor 154Diagonal bracing 156 Projections 158 Holes in projections

What is claimed is:
 1. A connector assembly, comprising an upperconnector coupled to a lower connector and a gusset plate sandwichedbetween the upper and lower connectors, the lower connector comprising:a lower connector body having a lower connector body column receivingend and a lower connector body gusset contact end, the column receivingend being adapted for receiving a first end of a first module frame andthe gusset contact end being adapted for coupling to the gusset plate;at least a pair of lower connector arms, each lower connector armcoupled to and extending from the lower connector body and having lowerconnector arm inner face, a lower connector arm outer face, a lowerconnector arm gusset contact face, a lower connector arm load bearingface and a lower connector arm beam contact face, the beam contact facebeing positioned distal from the lower connector body, each lowerconnector arm having at least one fixing aperture on the load bearingface for receiving a fastening means to couple the lower connector tothe upper connector, and each lower connector arm having a hole formedthat extends from the lower connector arm inner face to the lowerconnector arm outer face; and a lower connector arm boss coupled to andextending from the beam contact face of each arm, the boss having alower connector arm weld receiving bevel extending from the distal endof the arm; the upper connector comprising: an upper connector bodyhaving an upper connector body column receiving end and an upperconnector body gusset contact end, the column receiving end beingadapted for receiving a first end of a second module frame and thegusset contact end being adapted for coupling to the gusset plate; atleast a pair of upper connector arms, each upper connector arm coupledto and extending from the upper connector body and having an upperconnector arm inner face, an upper connector arm outer face, an upperconnector arm gusset contact face, an upper connector arm load bearingface and an upper connector arm beam contact face, the beam contact facebeing positioned distal from the upper connector body; each upperconnector arm having at least one upper connector arm fixing aperturefor receiving a fastening means to couple the lower connector to theupper connector and at least one upper connector arm gusset couplingaperture for receiving a second fastening means to couple the upperconnector to the gusset plate, and each upper connector arm having ahole formed that extends from the upper connector arm inner face to theupper connector arm outer face; and an upper connector arm boss coupledto and extending from the upper connector arm beam contact face of eachupper connector arm, the boss having an upper connector arm weldreceiving bevel extending from the distal end of the arm; the gussetplate comprising: a gusset plate first face, a gusset plate second faceand gusset plate through holes for receiving the coupling and fasteningmeans to couple the upper connector and the lower connector; furthercomprising a second lower connector coupled to the lower connector and asecond upper connector, with the gusset plate positioned between thesecond lower connector and the second upper connector; the second lowerconnector comprising: a second lower connector body having a secondlower connector body column receiving end and a second lower connectorbody gusset contact end, the second lower connector body columnreceiving end being adapted for receiving a first end of a third moduleframe and the second lower connector body gusset contact end beingadapted for coupling to the gusset plate; at least a pair of secondlower connector arms, each second lower connector arm coupled to andextending from the second lower connector body and having a second lowerconnector arm inner face, a second lower connector arm outer face, asecond lower connector arm gusset contact face, a second lower connectorarm load bearing face and a second lower connector arm beam contactface, the second lower connector arm beam contact face being positioneddistal from the second lower connector body, each second lower connectorarm having at least one fixing aperture on the second lower connectorarm load bearing face for receiving a fastening means to couple thesecond lower connector to the second upper connector, and each secondlower connector arm having a hole formed that extends from the secondlower connector arm inner face to the second lower connector arm outerface; and a second lower connector arm boss coupled to and extendingfrom the second lower connector arm beam contact face of each arm, thesecond lower connector arm boss having a second lower connector arm weldreceiving bevel extending from the distal end of the arm; and the secondupper connector comprising: a second upper connector body having asecond upper connector body column receiving end and a second upperconnector body gusset contact end, the second upper connector columnreceiving end being adapted for receiving a first end of a fourth moduleframe and the second upper connector gusset contact end being adaptedfor coupling to the gusset plate; at least a pair of second upperconnector arms, each second upper connector arm coupled to and extendingfrom the second upper connector body and having a second upper connectorarm inner face, a second upper connector arm outer face, a second upperconnector arm gusset contact face, a second upper connector arm loadbearing face and a second upper connector arm beam contact face, thesecond upper connector arm beam contact face being positioned distalfrom the second upper connector body; each second upper connector armhaving at least one second upper connector arm fixing aperture forreceiving a fastening means to couple the second lower connector to thesecond upper connector and at least one second upper connector armgusset coupling aperture for receiving a second fastening means tocouple the second upper connector to the gusset plate, and each secondupper connector arm having a hole formed that extends from the secondupper connector arm inner face to the second upper connector arm outerface; and a second upper connector arm boss coupled to and extendingfrom the second upper connector arm beam contact face of each upperconnector arm, the second upper connector arm boss having a second upperconnector arm weld receiving bevel extending from the distal end of thesecond upper connector arm; wherein the second lower connector arm outerface is proximate the lower connector arm outer face, the second upperconnector arm outer face is proximate the upper connector arm outerface, and the second lower connector arm gusset contact face isproximate the second upper connector arm load bearing face; and furthercomprising a second gusset plate positioned on the lower connector armload bearing face and the second lower connector arm load bearing face,the second gusset plate has a plurality of apertures, the lowerconnector arm load bearing face having a hole aligned with one of theplurality of apertures on the second gusset plate, and the second lowerconnector arm load bearing face having a hole aligned with one of theother plurality of apertures; and a fastening means engaging theaperture on the second gusset plate, where the aperture is aligned withthe hole on the lower connector load bearing face for affixing thesecond gusset plate to the lower connector, and a second fastening meansengaging another aperture of the plurality of apertures on the secondgusset plate, where the other aperture is aligned with the hole on thesecond lower connector arm load bearing face for affixing the secondgusset plate to the second lower connector.
 2. The connector assembly ofclaim 1, wherein a fastening means engages the hole in the lowerconnector arm inner face and the second lower connector arm inner faceand couples the lower connector arm to the second lower connector arm.3. The connector assembly of claim 1, wherein a second fastening meansengages the hole in the upper connector arm inner face and the secondupper connector arm inner face and couples the upper connector arm tothe second upper connector arm.
 4. The connector assembly according toclaim 1, further comprising: a projection coupled to and extending fromthe second gusset plate; the projection extending in a direction awayfrom the lower connector arm load bearing face.
 5. The connectorassembly according to claim 1, further comprising a brace coupled to theprojection.